Method of producing a fouling-proof structure

ABSTRACT

A method of producing a fouling-proof structure, comprising steps of a) coating an alcohol-resistant combination on a substrate and then drying the alcohol-resistant combination at 80-160° C. to form an alcohol-resistant layer; and b) coating a water-based fouling-proof combination on the alcohol-resistant layer and then drying the water-based fouling-proof combination above 140° C. to form a water-based fouling-proof layer, wherein the alcohol-resistant layer is formed by curing an alcohol-resistant combination, and the alcohol-resistant combination comprises polyurethane resin, wherein the water-based fouling-proof layer is formed by curing a water-based fouling-proof combination, and the water-based fouling-proof combination comprises polyurethane resin, water, polymerized siloxanes, water-based PTFE and silicone oil.

CROSS-REFERENCE TO RELATED APPLICATION

This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No(s).108127961 filed in Taiwan, R.O.C. onAug. 6, 2019 and Patent Application No(s). 108145528 filed in Taiwan,R.O.C. on Dec. 12, 2019, the entire contents of which are herebyincorporated by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present disclosure relates to a method of producing a fouling-proofstructure, and in particular to a method of producing a fouling-proofstructure on a synthetic leather surface.

2. Description of the Related Art

Use of synthetic leather is wide and increasing steadily year by year.However, the use of synthetic leather in garments, furniture, wallmaterials and public space is confronted with problems. For example, thesurface of synthetic leather is susceptible to dirt or graffiti, whichis unremovable and, in consequence, the resultant unattractiveappearance of the synthetic leather leads to shortened service life andthus poses an environmental burden. Therefore, it is important toprovide a fouling-proof structure effective in preventing dirt,cleaning, and preventing detergent-induced damage. The fouling-proofstructure will extend the service life of related products, lower theirreplacement rates, lessen their impacts on the environment, and thusconvert the products into green.

BRIEF SUMMARY OF THE INVENTION

In view of the aforesaid drawbacks of the prior art, an objective of thepresent disclosure is to provide a method of producing a fouling-proofstructure.

To achieve at least the above objective, the present disclosure providesa method of producing a fouling-proof structure, comprising steps of: a)coating an alcohol-resistant combination on a substrate and then dryingthe alcohol-resistant combination at 80-160° C. to form analcohol-resistant layer; and b) coating a water-based fouling-proofcombination on the alcohol-resistant layer and then drying thewater-based fouling-proof combination above 140° C. to form awater-based fouling-proof layer, wherein the alcohol-resistant layer isformed by curing an alcohol-resistant combination, and thealcohol-resistant combination comprises polyurethane resin, and whereinthe water-based fouling-proof layer is formed by curing a water-basedfouling-proof combination, and the water-based fouling-proof combinationcomprises polyurethane resin, water, polymerized siloxanes, water-basedPTFE and silicone oil.

Regarding the method, the alcohol-resistant combination comprises: 30-50weight percent of polyether and polyester aliphatic water-basedpolyurethane resin; and further comprises 40-70 weight percent of water.

Regarding the method, the alcohol-resistant combination furthercomprises: 0.01-3 weight percent of wetting agent; 0.01-2 weight percentof aziridine crosslinker; 0.01-1 weight percent of antifoaming agent;and 0.5-2.5 weight percent of polycarbodiimide crosslinker.

Regarding the method, the alcohol-resistant combination comprises: 70-90weight percent of hydrolysis-resistant, yellowing-resistant polyetherpolyurethane resin; and further comprises: 5-15 weight percent ofmelamine type two-component crosslinker; and 4-15 weight percent oftwo-component chemical promoter.

Regarding the method, the alcohol-resistant combination furthercomprises:

0.01-2 weight percent of matting agent.

Regarding the method, the water-based fouling-proof combinationcomprises: 5-40 weight percent of polyether and polyester aliphatic,hydrolysis-resistant, water-based polyurethane resin; 40-70 weightpercent of water; 5-30 weight percent of polymerized siloxanes; 1-10weight percent of water-based PTFE; and 1-10 weight percent of siliconeoil.

Regarding the method, the water-based fouling-proof combination furthercomprises: 0.1-3 weight percent of isocyanate crosslinker; 0.1-3 weightpercent of tackifier; 0.1-3 weight percent of wetting agent; 0.01-3weight percent of antifoaming agent; 5-15 weight percent of leatherslipping agent; and 0.01-1 weight percent of matting agent.

The fouling-proof structure produced by the method is disposed on asubstrate. The alcohol-resistant layer is disposed between thewater-based fouling-proof layer and the substrate. Besides, thesubstrate can be made of fabric, polyurethane (PU) or polyvinyl chloride(PVC). In a variant embodiment, the substrate is made of fabric, PU,water-based PU, PVC, semi PU/PVC, thermoplastic polyurethane (TPU),thermoplastic olefin (TPO), thermoplastic vulcanizate (TPV),thermoplastic styrene (TPS), thermoplastic polyether ester elastomer(TPEE), thermoplastic polyamide (TPA), or a combination thereof.

Regarding the method, the drying in step a) and step b) lasts one tofive minutes. In a variant embodiment, the drying in step a) and step b)lasts three minutes.

Regarding the method, the alcohol-resistant combination and thewater-based fouling-proof combination are coated on the substrate andthe alcohol-resistant layer by spraying-coating, respectively.

Regarding the method, the way of coating includes spraying-coating,soaking-coating, showering-coating, painting-coating, rotating-coating,vacuum-coating, rolling-coating and direct coating.

The fouling-proof structure produced by the method of the presentdisclosure is applicable to the surface of synthetic leather. None ofthe hotel ballpoint pen, ballpoint pen or gel pen is able to cause astain to the surface of the synthetic leather which has thefouling-proof structure produced by the method of the presentdisclosure; even if it is, the stain can be easily removed to a greatextent with dry cloth, and then the remainder of the stain can also beremoved by commercial detergents or alcohol solution, so as to restorethe appearance of the surface of the synthetic leather material.

According to the prior art, the conventional fouling-proof structureformed on the synthetic leather surface does not have a basal layer madeof an alcohol-resistant material, and thus the structure is likely to bedamaged or has its fouling-proof performance quickly decayed when it haswiped with solvent. It is because the bonding between the fouling-proofmaterial and the synthetic leather to be protected is so worse that thelayer readily becomes a disposable fouling-proof layer and thus lackscommercial value and practicability.

By contrast, the fouling-proof structure produced by the method of thepresent disclosure has a basal layer made of an alcohol-resistantmaterial beneath the water-based fouling-proof material. In a preferredembodiment, the water-based fouling-proof material undergoes aspraying-coating process before the alcohol-resistant layer is curing(reacts with the substrate surface completely), and the two layers aresimultaneously cured together (react completely) at high temperature.The alcohol-resistant layer is graffiti-proof. The purpose of theaforesaid processing and reaction process is to avoid a condition: afterthe alcohol-resistant layer has cured at high temperature completely,the water-based fouling-proof material can no longer be bonded to thealcohol-resistant layer perfectly, thereby causing the fouling-prooflayer to detach.

The fouling-proof structure produced by the method of the presentdisclosure comprises a water-based fouling-proof layer and analcohol-resistant layer, and it can be the protective layers on thesubstrates made of various materials.

In a variant embodiment, it is only when the synthetic leather materialwhich is covered with the fouling-proof structure produced by the methodcomprising a water-based fouling-proof layer and an alcohol-resistantlayer is wiped repeatedly at least 30 times with alcohol solution orcommercial detergents and then begins to decrease the performance of itsfouling-proof structure.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to clarify the description, the thickness and size of eachlayer shown in the drawings are enlarged, omitted or schematicallydepicted. The drawings are not drawn to scale.

FIG. 1 is a scheme of a fouling-proof structure produced by the methodof the present disclosure and a substrate according to embodiment 1 ofthe present disclosure.

FIG. 2 is a picture of the fouling-proof structure produced by themethod of the present disclosure and the substrate according toembodiment 1 of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

To well understand the purpose, characteristics, and effects of thispresent disclosure, embodiments together with the detailed descriptionsand the attached tables of the present disclosure are provided.

Embodiment 1-1

The process of producing the fouling-proof structure in this embodimentis as follows:

-   -   a) coating an alcohol-resistant combination on the substrate and        drying the alcohol-resistant combination at 90-120 C for one to        five minutes to form the alcohol-resistant layer;    -   b) coating a water-based fouling-proof combination on the        alcohol-resistant layer and drying the water-based fouling-proof        combination above 140° C. for one to five minutes to form the        water-based fouling-proof layer.

The drying temperature and duration in step a) and step b) only serveexemplary purposes and thus must not be interpreted in such a manner tobe restrictive of the scope of the present disclosure. Hence, personsskilled in the art can appropriately adjust the drying temperature andduration in step a) and step b) as needed without departing from thescope of the claims of the present disclosure. In a variant embodiment,the drying in step b) takes place at 140-145° C.

In this embodiment, the alcohol-resistant combination and water-basedfouling-proof combination are coated by means of spraying-coating, butthe present disclosure is not limited thereto; hence, persons skilled inthe art can select an appropriate method of coating as needed. Accordingto the present disclosure, the means of coating for use in the method ofproducing a fouling-proof structure includes but is not limited to:spraying-coating, soaking-coating, showering-coating, painting-coating,rotating-coating, vacuum-coating, rolling-coating and direct coating.

Referring to FIG. 1, a fouling-proof structure 10 produced by the methodin embodiment 1 comprises an alcohol-resistant layer 12 and awater-based fouling-proof layer 13 disposed on the alcohol-resistantlayer 12. In this embodiment, the fouling-proof structure 10 is disposedon a substrate 20. The alcohol-resistant layer 12 is disposed betweenthe water-based fouling-proof layer 13 and the substrate 20.

In this embodiment, the substrate 20 is water-based PU syntheticleather, but the present disclosure is not limited thereto. In a variantembodiment, the substrate is fabric, polyurethane (PU) leather,water-based PU leather, polyvinyl chloride (PVC) leather, semi PU/PVCleather, thermoplastic polyurethane (TPU) leather, thermoplastic olefin(TPO), thermoplastic vulcanizate (TPV), thermoplastic styrene (TPS),thermoplastic polyether ester elastomer (TPEE), thermoplastic polyamide(TPA), or a combination thereof.

In this embodiment, the alcohol-resistant layer 12 is formed by curingan alcohol-resistant combination A. The constituents of thealcohol-resistant combination A are enumerated in Table 1 below.

TABLE 1 weight percent alcohol- alcohol- alcohol- resistant resistantresistant combi- combi- combi- constituent nation A nation B nation Caliphatic water-based PU resin 30 42 50 (polyether & polyester type)(model number: F-363, purchased from Chain Chemical Co., Ltd.) wettingagent (model number: 0.5 1.5 3 OFX-5211, purchased from Guang zhouHT-Chemical Co., Ltd.) aziridine crosslinker (model 1 1.5 2 number:PZ-33, purchased from PolyAziridine LLC) antifoaming agent (modelnumber: 0 0.5 1 A5757, purchased from Sigma- Aldrich) polycarbodiimidecrosslinker 0.7 1.4 2.1 (model number: V-02-L2, purchased from An FongDevelopment Co., Ltd.) water 67.8 53.1 41.9

In this embodiment, the water-based fouling-proof layer 13 is formed bycuring the water-based fouling-proof combination A. The constituents ofthe water-based fouling-proof combination A are enumerated in Table 2below.

TABLE 2 weight percent water- water- water- based based based fouling-fouling- fouling- proof proof proof combi- combi- combi- constituentnation A nation B nation C aliphatic & hydrolysis-resistant 6.6 19.428.9 water-based PU resin (polyether & polyester type) (model number:JW-25A-2, purchased from Jiuh Yi Chemical Industrial Co. Ltd.)isocyanate crosslinker (model 0.6 1.9 2.9 number: EC-385, purchased fromSiwoChem) water 58.5 50.2 43.6 polymerized siloxanes (model 15.3 13.4 12number: PA-8316, purchased from Guang zhou HT-Chemical Co., Ltd.)water-based 2 1.1 1 polytetrafluoroethylene (PTFE) (model number:Teflon ™ PTFE, purchased from Dupont Chemours) silicone oil (modelnumber: 2.0 1.7 1.4 85409-IL, purchased from Sigma- Aldrich) tackifier(model number: CA- 0.5 0.4 0.3 909, purchased from Xuanning ChemicalTechnology) wetting agent (model number: 0.3 0.2 0.2 OFX-5211, purchasedfrom Guang zhou HT-Chemical Co., Ltd.) antifoaming agent (model number:0.1 0.1 0.1 A5757, purchased from Sigma- Aldrich leather slipping agent(model 13.1 11.1 9.6 number: AQUADERM ADDITIVE GF, purchased fromLanxess (Changzhou) Co., Ltd.) matting powder (model number: 1 0.5 0ACEMATT ® TS-100, purchased from EVONIK)

The product model numbers, suppliers, and weight percents of theconstituents enumerated in Table 1 and Table 2 only serve exemplarypurposes but must not be interpreted in such a manner to be restrictiveof the scope of the present disclosure. Hence, persons skilled in theart can select appropriate product model numbers and suppliers of theconstituents and adjust appropriate weight percents as needed withoutdeparting from the scope of the claims of the present disclosure. Inthis embodiment, for exemplary purposes, matting powder is used as thematting agent, but the present disclosure is not limited thereto, andthus it is feasible to use any other types (for example, liquid) ofmatting agent. In a variant embodiment, the alcohol-resistantcombination does not include any wetting agent, aziridine crosslinkerand antifoaming agent. In a variant embodiment, the water-basedfouling-proof combination does not include any antifoaming agent andmatting agent.

FIG. 2 is a picture taken of the fouling-proof structure 10 produced bythe method of the present disclosure and the substrate 20 according toembodiment 1 of the present disclosure. The picture shows four layersarranged from top to bottom as follows: (a) a top layer is thefouling-proof structure 10 which comprises the alcohol-resistant layer12 and the water-based fouling-proof layer 13; the substrate 20includes: (b) a surface layer which comprises the surface of water-basedPU; (c) a middle layer which comprises water-based PU foam; and (d)fabric.

Embodiment 1-2

When it conies to the fouling-proof structure and the process ofproducing the same, embodiment 1-2 differs from embodiment 1-1 asfollows: in embodiment 1-2, the alcohol-resistant layer is formed bycuring an alcohol-resistant combination B, and the constituents of thealcohol-resistant combination B are enumerated in Table 1; and thewater-based fouling-proof layer is formed by curing the water-basedfouling-proof combination B, and the constituents of the water-basedfouling-proof combination B are enumerated in Table 2 above.

Embodiment 1-3

When it comes to the fouling-proof structure and the process ofproducing the same, embodiment 1-3 differs from embodiment 1-1 asfollows: in embodiment 1-3, the alcohol-resistant layer is formed bycuring an alcohol-resistant combination C; the constituents of thealcohol-resistant combination C are enumerated in Table 1 above; and thewater-based fouling-proof layer is formed by curing the water-basedfouling-proof combination C, and the constituents of the water-basedfouling-proof combination C are enumerated in Table 2 above.

Embodiment 2-1

The fouling-proof structure in embodiment 2-1 comprises: analcohol-resistant layer; and a water-based fouling-proof layer disposedon the alcohol-resistant layer. In this embodiment, the fouling-proofstructure is disposed on a substrate, and the alcohol-resistant layer isdisposed between the water-based fouling-proof layer and the substrate.

In this embodiment, the substrate is solvent-based PU synthetic leather,but the present disclosure is not limited thereto. In a variantembodiment, the substrate is fabric, polyurethane (PU) leather,water-based PU leather, polyvinyl chloride (PVC) leather, semi PU/PVCleather, thermoplastic polyurethane (TPU) leather, thermoplastic olefin(TPO), thermoplastic vulcanizate (TPV), thermoplastic styrene (TPS),thermoplastic polyether ester elastomer (TPEE), thermoplastic polyamide(TPA), or a combination thereof.

The process flow of producing the fouling-proof structure in thisembodiment comprises the steps as follows:

-   -   a) coating an alcohol-resistant combination on a substrate and        then drying the alcohol-resistant combination at 90-130° C. for        one to five minutes to form an alcohol-resistant layer; and    -   b) coating a water-based fouling-proof combination on the        alcohol-resistant layer and then drying the water-based        fouling-proof combination above 140′C for one to five minutes to        form a water-based fouling-proof layer.

The drying temperatures and durations in step a) and step b) only serveexemplary purposes but must not be interpreted in such a manner to berestrictive of the scope of the present disclosure. Persons skilled inthe art can appropriately adjust the drying temperatures and durationsin step a) and step b) as needed without departing from the scope of theclaims of the present disclosure. In a variant embodiment, the drying instep b) takes place at 140-145° C.

In this embodiment, the alcohol-resistant combination and water-basedfouling-proof combination are coated by spraying-coating, but thepresent disclosure is not limited thereto, and thus persons skilled inthe art may choose an appropriate way of coating as needed. The way ofcoating for use in the method of producing a fouling-proof structureaccording to the present disclosure includes, but is not limited to,spraying-coating, soaking-coating, showering-coating, painting-coating,rotating-coating, vacuum-coating, rolling-coating and direct coating.

In this embodiment, the alcohol-resistant layer is formed by curing analcohol-resistant combination D, and the constituents of thealcohol-resistant combination D are enumerated in Table 3 below.

TABLE 3 weight percent alcohol- alcohol- alcohol- resistant resistantresistant combi- combi- combi- constituent nation D nation E nation Fhydrolysis-resistant & yellowing- 76 82 88 resistant PU resin (polyethertype) (model number: SC-8200G, purchased from Guangzhou SongjeongChemical Co., Ltd.) two-component crosslinker 11 8.2 5.3 (melamine type)(model number: SH-82, purchased from Guangzhou Songjeong Chemical Co.,Ltd.) matting powder (model number: 1.5 1.6 1.8 ACEMATT ® TS-100,purchased from EVONIK) two-component chemical promoter 11.5 8.2 4.9(model number: SE-82, purchased from Guangzhou Songjeong Chemical Co.,Ltd.)

In this embodiment, the water-based fouling-proof layer is formed bycuring the water-based fouling-proof combination D, and the constituentsof the water-based fouling-proof combination D are enumerated in Table 4below.

TABLE 4 weight percent water- water- water- based based based fouling-fouling- fouling- proof proof proof combi- combi- combi- constituentnation D nation E nation F aliphatic & hydrolysis-resistant, 6.6 19.428.9 water-based PU resin (polyether & polyester type) (model number:JW-25A-2, purchased from Jiuh Yi Chemical Industrial Co. Ltd.)isocyanate crosslinker (model 0.6 1.9 2.9 number: EC-385, purchased fromSiwoChem) water 58.5 50.2 43.6 polymerized siloxanes (model 15.3 13.4 12number: PA-8316, purchased from Guang zhou HT-Chemical Co., Ltd.)water-based 2 1.1 1 polytetrafluoroethylene (PTFE) (model number:Teflon ™ PTFE, purchased from Dupont Chemours) silicone oil (modelnumber: 2.0 1.7 1.4 85409-IL, purchased from Sigma- Aldrich) tackifier(model number: CA- 0.5 0.4 0.3 909, purchased from Xuanning ChemicalTechnology) wetting agent (model number: 0.3 0.2 0.2 OFX-5211, purchasedfrom Guang zhou HT-Chemical Co., Ltd.) antifoaming agent (model number:0.1 0.1 0.1 A5757, purchased from Sigma- Aldrich) leather slipping agent(model 13.1 11.1 9.6 number: AQUADERM ADDITIVE GF, purchased fromLanxess (Changzhou) Co., Ltd.) matting powder (model number: 1 0.5 0ACEMATT ® TS-100, purchased from EVONIK)

The product model numbers, suppliers, and weight percents of theconstituents enumerated in Table 3 and Table 4 only serve exemplarypurposes but must not be interpreted in such a manner to be restrictiveof the scope of the present disclosure. Persons skilled in the art canselect appropriate product model numbers and suppliers of theconstituents and adjust appropriate weight percents as needed withoutdeparting from the scope of the claims of the present disclosure. Inthis embodiment, matting powder is used as the matting agent forexemplary purposes, but the present disclosure is not limited thereto,and thus it is feasible to use any other types (for example, liquid) ofmatting agent. In a variant embodiment, the alcohol-resistantcombination does not include any matting agent. In a variant embodiment,the water-based fouling-proof combination does not include anyantifoaming agent and matting agent.

Embodiment 2-2

When it comes to the fouling-proof structure and the process ofproducing the same, embodiment 2-2 differs from embodiment 2-1 asfollows: in embodiment 2-2, the alcohol-resistant layer is formed bycuring an alcohol-resistant combination E, and the constituents of thealcohol-resistant combination E are enumerated in Table 3 above; and thewater-based fouling-proof layer is formed by curing the water-basedfouling-proof combination E, and the constituents of the water-basedfouling-proof combination E are enumerated in Table 4 above.

Embodiment 2-3

When it comes to the fouling-proof structure and the process ofproducing the same, embodiment 2-3 differs from embodiment 2-1 asfollows: in embodiment 2-3, the alcohol-resistant layer is formed bycuring an alcohol-resistant combination F, and the constituents of thealcohol-resistant combination F are enumerated in Table 3 above; and thewater-based fouling-proof layer is formed by curing the water-basedfouling-proof combination F, and the constituents of the water-basedfouling-proof combination F are enumerated in Table 4 above.

Test

A test is performed on the fouling-proof structure produced by themethods of embodiments 1-1 through 1-3 and 2-1 through 2-3. First, theability of the fouling-proof structure produced by the methods ofembodiments 1-1 through 1-3 and 2-1 through 2-3 is testified by specificstaining agents. Next, after a specific period of time has passed, thecontaminated fouling-proof structure produced by the method of presentdisclosure is wiped. After that, remnants of stains are assessed interms of their extent, and the result of the assessment is shown inTable 5 below.

TABLE 5 stain dwell time within 3 minutes 3 hours later 24 hours laterpreclean- preclean- preclean- wipe wipe wipe staining agents, with dry95% with dry 95% with dry 95% (class) cloth ethanol* cloth ethanol*cloth ethanol* Embodiment 1-1 denim dye 5 5 5 5 5 5 (color migration)hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4 4.5 black tea 5 5 5 5 55 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 5 5 4 4.5 Coca-Cola5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 1-2 denim dye 5 5 5 5 5 5(color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4.5 5black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 55 5 4.5 5 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 1-3denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5marker 5 5 4.5 5 3.5 4 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup5 5 5 5 5 5 mustard 5 5 4.5 5 3.5 4 Coca-Cola 5 5 5 5 5 5 soy sauce 5 55 5 5 5 Embodiment 2-1 denim dye 5 5 5 5 5 5 (color migration) hotelballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4 4.5 black tea 5 5 5 5 5 5coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 5 5 5 4 4.5 Coca-Cola 55 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 2-2 denim dye 5 5 5 5 5 5(color migration) hotel ballpoint pen 5 5 5 5 5 5 marker 5 5 5 5 4.5 5black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup 5 5 5 5 5 5 mustard 5 55 5 4.5 5 Coca-Cola 5 5 5 5 5 5 soy sauce 5 5 5 5 5 5 Embodiment 2-3denim dye 5 5 5 5 5 5 (color migration) hotel ballpoint pen 5 5 5 5 5 5marker 5 5 4.5 5 3.5 4 black tea 5 5 5 5 5 5 coffee 5 5 5 5 5 5 ketchup5 5 5 5 5 5 mustard 5 5 4.5 5 3.5 4 Coca-Cola 5 5 5 5 5 5 soy sauce 5 55 5 5 5 *wipe with dry cloth and then with 95% ethanol

Rating System:

-   Class 5 No evidence of stain present-   Class 4 Slight evidence of stain present-   Class 3 Noticeable evidence of stain present-   Class 2 Considerable evidence of stain present-   Class 1 Excessive evidence of stain present

In Table 5, the cardinal number of the class assessment is 0.5. Forexample, 4.5 indicates that the fouling-proof class stands between class4 and class 5. After being wiped with 95% ethanol, the fouling-proofstructure produced by the method of present disclosure contaminated bythe staining agents enumerated in Table 5 has either no evidence orslight evidence of stain present. Hence, the fouling-proof structureproduced by the method of the present disclosure is capable ofperforming stain resistibility.

The main differences in synthetic leather processing between thefouling-proof structure produced by the method of the present disclosureand a conventional fouling-proof material disclosed in the prior art areas follows:

-   1. Most of the commercial fouling-proof materials suitable for    synthetic leather processing are solvent-based two-component resin.    Their constituents include organic solvents, and thus they are    confronted by the volatilization of volatile organic compounds    (VOC).-   2. Commercial fouling-proof materials suitable for use with leather    are high-modulus resins. By contrast, the water-based PU used in the    fouling-proof structure produced by the method of the present    disclosure is low-modulus resin. The issue of the ability of flex,    which occurs in soft leather processing, is typical in the    commercial fouling-proof materials but not in the fouling-proof    structure produced by the method of the present disclosure.-   3. The ballpoint pen is hard to write on the synthetic leather    coated with the fouling-proof material of the present disclosure.    Even if it can do so, the stain can be wiped off easily. By    contrast, the ballpoint pen can write on the synthetic leather    coated with commercial fouling-proof materials easily, and the stain    should wipe with detergent in three hours (better not more than 24    hours). Otherwise, the stain cannot be removed anymore.-   4. There exists the issue of denim dye migration in commercial    water-based fouling-proof material.-   5. Commercial fouling-proof materials are not always suitable for    all kinds of synthetic leather finishing.-   6. The fouling-proof structure produced by the method of the present    disclosure comprises a water-based fouling-proof layer and an    alcohol-resistant layer which are coupled together to form a    stronger protective layer. Hence, until the fouling-proof structure    produced by the method of the present disclosure is wiped repeatedly    with alcohol solution at least 30 times, its fouling-proof structure    starts to decay.

The fouling-proof structure produced by the method of the presentdisclosure has advantages as follows:

-   1. The main residues, water-based PU resin in the process of the    fouling-proof structures can be reused.-   2. The fouling-proof structure produced by the method of the present    disclosure is odorless, non-toxic, free of VOC,    environment-friendly, and thus conducive to environmental    protection.-   3. The fouling-proof structure of the present disclosure is still    high yellowing-resistant and free of burnt smell after    high-temperature embossing process.

While the present disclosure has been described by means of specificembodiments, numerous modifications and variations could be made theretoby those skilled in the art without departing from the scope and spiritof the present disclosure set forth in the claims.

What is claimed is:
 1. A method of producing a fouling-proof structure,comprising steps of: a) coating an alcohol-resistant combination on asubstrate and then drying the alcohol-resistant combination at 80-160°C. to form an alcohol-resistant layer; and b) coating a water-basedfouling-proof combination on the alcohol-resistant layer and then dryingthe water-based fouling-proof combination above 140° C. to form awater-based fouling-proof layer, wherein the alcohol-resistant layer isformed by curing an alcohol-resistant combination, and thealcohol-resistant combination comprises polyurethane resin, and whereinthe water-based fouling-proof layer is formed by curing a water-basedfouling-proof combination, and the water-based fouling-proof combinationcomprises polyurethane resin, water, polymerized siloxanes, water-basedPTFE and silicone oil.
 2. The method of claim 1, wherein thealcohol-resistant combination comprises: 30-50 weight percent ofpolyether and polyester aliphatic water-based polyurethane resin; andfurther comprises: 40-70 weight percent of water.
 3. The method of claim2, wherein the alcohol-resistant combination further comprises: 0.01-3weight percent of wetting agent; 0.01-2 weight percent of aziridinecrosslinker; 0.01-1 weight percent of antifoaming agent; and 0.5-2.5weight percent of polycarbodiimide crosslinker.
 4. The method of claim1, wherein the alcohol-resistant combination comprises: 70-90 weightpercent of hydrolysis-resistant, yellowing-resistant polyetherpolyurethane resin; and further comprises: 5-15 weight percent ofmelamine type two-component crosslinker; and 4-15 weight percent oftwo-component chemical promoter.
 5. The method of claim 4, wherein thealcohol-resistant combination further comprises: 0.01-2 weight percentof matting agent.
 6. The method of claim 1, wherein the water-basedfouling-proof combination comprises: 5-40 weight percent of polyetherand polyester aliphatic, hydrolysis-resistant, water-based polyurethaneresin; 40-70 weight percent of water; 5-30 weight percent of polymerizedsiloxanes; 1-10 weight percent of water-based PTFE; and 1-10 weightpercent of silicone oil.
 7. The method of claim 6, wherein thewater-based fouling-proof combination further comprises: 0.1-3 weightpercent of isocyanate crosslinker; 0.1-3 weight percent of tackifier;0.1-3 weight percent of wetting agent; 0.01-3 weight percent ofantifoaming agent; 5-15 weight percent of leather slipping agent; and0.01-1 weight percent of matting agent.
 8. The method of claim 1,wherein the fouling-proof structure is disposed on a substrate, and thealcohol-resistant layer is disposed between the water-basedfouling-proof layer and the substrate, the substrate being made offabric, polyurethane, polyvinyl chloride, thermoplastic polyurethane,thermoplastic olefin, thermoplastic vulcanizate, thermoplastic styrene,thermoplastic polyether ester elastomer or thermoplastic polyamide. 9.The method of claim 1, wherein the alcohol-resistant combination and thewater-based fouling-proof combination are coated on the substrate andthe alcohol-resistant layer by spraying-coating, respectively.
 10. Themethod of claim 1, wherein the drying in step a) and step b) lasts oneto five minutes.